Now I had to find a way to glue it all back together and rebuild up the part that I ground down and had weakened with the heat gun. I found some stuff at the local boating store that worked well. After about 60 clamps I got it all glued up. You can see in some of the pictures of around the window opening of how much it actually had to be bent to have the hardware fit inside the hatch. After all that was done and the built up area was smoothed out and reformed to the shape it should be I had to make the window fit. Now right from the start before I touched it there was no way the window gasket would fit on the hatch. The fiberglass was a 1/4" too thick in most areas, so that had to be ground down to make it fit.
All in all I figure I have about 30 hours into this hatch.
I can understand maybe having to trim a bit here and there but for the amount they are selling these for it seems unreasonable to me to have to
-drill out and elongate the holes for the hinges
-grind down the window flange to an acceptable size
-completely reshape the bottom half to allow a STOCK handle to fit
-add the sheet metal reinforcement that the hatch handle bolts to since it wasn't there
-significantly enlarge the hinge pocket holes
...and the area where the supports arms attach to is so completely malformed there is no way I can repair it aside from cutting the whole thing out.
